Turbine Simulator

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TITLE

Design and Manufacturing of Impulse TurbineLaboratory Experimental Setup.

Supervisor: Sir Jamil

Internee: Ali Waqas Ahmad



Preface

To day the Pakistan is confronting the situation of energy crisis, there is a need to take the

research in the energy sector to cure this problem of the country. God blessed Pakistan with

ample sources of water but it is our bad luck that we use only 13%.sources of water. Our river¶s

flow has the capacity of 55000 Mega Watts. In this back ground I proposed the laboratory

experimental setup of Impulse Turbine to enhance the practical knowledge of my self as well as

any student of the concerned field regarding Hydal Power.

To complete the Project I decided the division of project in to different steps which I explained

in the contents. Generally Design and manufacturing are the main features of this project. My

design is totally based on the different formulas available in different literature books on fluid

mechanics, which I mentioned in the reference area at the end. One thing which is important is

that my design configuration is not authorized yet it brings pleasure for me if some one picks my

faults and corrects me because there is always a need to improve.

Second Major part is manufacturing, which is a difficult task for me because I have no

experience before. But some one says:´ God helps those who help themselves´. Manufacturing

contains different important steps generally drawings, cost estimation, quotations and machining

etc. To manufacture this apparatus I went to Chitral Engineering Works and asked them about

the manufacturing of the Project. Chitral works agreed and in this way I was able to convert my

Design into physical structure, this is a simple story of my journey from Newton Law to Light. I

mean from theory of Turbine to actual power output which is again converted into light by using

the Bulbs.

Third part is performing the experiments, to enhance the knowledge of Turbine Characteristics of impulse Turbine. In the contents area I list down the experiments and their detail on the

concerned pages.

Internee: Ali Waqas Ahmad

[email protected]





Contents

Chapter 1

Fundamental Concepts 5----------7

Chapter 2

Theory of Impulse turbine 8-----------11

Chapter 3

Design of Impulse Turbine 12-----------13

Chapter 4

Manufacturing of Impulse Turbine 14

Chapter 5

Experiments 20

Chapter 6

Future Proposed Work 20

Chapter 7

References 22



Fundamental Concepts

Fluid MachinesThose machines that either perform work on or extract work from the fluid. The Fluid machine

is an energy conversion device. It converts mechanical energy to thermal or pressure energy or

vise versa. This process is done through the dynamic interaction between a continuously flowingand a rotating machine component. Both momentum and energy transfer are involved. These

machines can be classified as1) direction of energy transfer, either from mechanical to thermal/pressure or vice versa;

2) type of fluid medium handled, either compressible or non compressible

Fluid Machines Classification Hierarchal Chart

Fluid Machines

Turbomachines Positive-displacement Others

Direction

Of energy

Transfer Pumping TurbinesDevices

Type

Of Fluid Pumps, Fans Hydraulic,Steam,windTurbines

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SystemA prescribed & identified quantity of matter.

Property

Any characteristic of a system that can be used to define its state.

Intensive Property

A property whose magnitude is independent of matter; like pressure, temperature, mass

density.

Extensive Property

A property whose magnitude is related to the total mass of the system.



Specific Weight

It is the ratio of the weight of the fluid to its unit volume

Mass density

It is the ratio of the mass of the fluid to its unit volume

Specific Gravity

It is the ratio of specific weight of the fluid to the specific weight of standard fluid like

water.

Specific volume

It is the ratio of volume of the fluid to its mass. More useful in compressible flow.

ViscosityThe resistance to flow because of internal resistance is called viscous, resistance.

And the property of fluid to offer resistance to relative motion b/w adjacent layers is called

Viscosity.

Cylindrical Coordinate SystemCoordinate system is used to locate points in space. If we encounter points in rectangular spacethen we utilize Cartesian coordinate system. But if we encounter points in cylindrical space then

we are required to follow cylindrical coordinates to locate these points in space. The followingfig depicts the cylindrical coordinate system

When the jet of water strikes the buckets its velocity will decompose into three components that

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are radial, axial and tangential components. So to construct the Velocity Triangles it is necessaryto have a sound knowledge of Cylindrical Coordinate system and Vector Algebra. In the theory

section I utilize this concept to derive the Velocity Triangles of the Buckets.

Vector Algebra

The branch of Mathematics in which we learn the laws of Vector manipulation i-e how to add,subtract, multiply etc the Vector Quantities. In this project I encounter the problems of vector directions, their component directions, addition, subtraction, resultant of components and the

angle between two Vector quantities. The vector quantity is Velocity.

Units of measurementThe science deals with different parameters including quantities and properties of any concernedsystem. There are three things which further simply the usage of these parameters, definition,

magnitude, direction. When I say Units of measurement it means that the way in which Irepresent the magnitude of any quantity specified by the definition. These quantities can be

further divided into two groups Basic quantities and derived quantities in the same way the units

are basic units and derived units. In this Project the Basic quantities are Mass, Time, length,Angle. And the derived Quantities are Area, Volume, Density, Pressure, Velocity, Torque,

Flow rate, Power, Momentum.

Once I know the basic and derived quantities of the system the second step is to choose themeasuring system. There are three system in the world to measure these quantities; S.I system,

U.S Customary Units, English Units. There is another concept of conversion; I can convert oneunit in one specific system to another specific system.

Theory of impulse Turbine



The theory of impulse turbine governs by the following concepts

Fluid StaticsWater Head

Flow RateTorque

Power Blade Angles

Velocity trianglesBernoulli¶s equation

Principal of Angular MomentumEquation of moment of momentum

Euler Turbo machine EquationTurbine Efficiencies

Maximum Turbine Efficiency

General Description

The following lines describe each and every concept in detail.

Fluid StaticsThis concept deals with the forces that are applied by the static fluid in rigid bodies. The fluid

property that is responsible for these forces is pressure. Which is a normal force exerted by thefluid per unit area. This property is further divided into Gauge and Absolute Pressure. Fluid

Statics also involved the concept of variation of pressure with respect to depth. There aredifferent devices used to measure this quantity like barometer and pressure gauges. Absolute and

Gauge Pressure are correlated by the following equation.

Pabs Patm Pvac

Patm Pabs Pgage

!

!

The second concept is variation of pressure with depth in the gravitational field. By the

application of integration the following equation comes out.

¨ p gh P !

Where h is the height of water column which is generally called head of water.

Flow RateThere are different types of fluid flow but here I considered Laminar flow of Water. The major field of Fluid Mechanics is the flow rate measurement. There are different devices to measure the

flow rate. But theoretically I have the formula from the Literature of Fluid Mechanics that is

TorqueIt is the Cross Product of Force and its Moment Arm. It is necessary to measure the output shaft

AREAVELOCITY FLOWRATE *!



power. Ouput power can be calculated as

wT Pout *!

Where w is Angular Velocity which is calculated by

W=60

**2 N pie

Where N is Rotation of shaft which is generally given in Rpm .

Power The basic definition of power is work done per unit time. In this project I encountered withdifferent powers Fluid power, Nozzle Power, Runner power, shaft power. But generally Input

power and Output Power. The formulas of these powers are listed in design section.

Blade AnglesThe angle through which the striking jet is deflected is called Blade Angle the optimum angle is

165 degree.

Velocity TrianglesWhen a jet strikes the buckets its jet velocity decomposes into three components i-e radial, axial

and tangential. As I know the Euler Equation we are required to have the relative Velocity andWhirl velocity to find the Power of Runner. So to obtain these components we construct the

velocity triangles to solve the Vectors. The velocity triangle of this impulse Turbine isconstructed in the design section.

Bernoulli¶s EquationIt is an approximate relation between, Pressure, Velocity and elevation which is given below.

! gzV

p

P

2

2^Constant

Turbine Efficiency

Turbine Efficiency = InputPower

r Out putPowe

General Description



The following figure shows the parts of Impulse turbine.

Parts of Impulse Turbine1) Nozzle2) Runner

3) Casing4) Buckets

5) Tail Race

Nozzle:This part is used to accelerate the flow and at the same time to convert the head of water

into kinetic energy. The main feature of the nozzle is its diameter which is the dia of exit jet. The

design of nozzle is based upon the Bernoulli¶s equation. In Pelton wheel there may be severalnozzles for the impact of jet.



Runner:This part is a disc on which buckets are attached. It is mounted on a shaft which passes

through bearings to allow the shaft move freely. The jet of water ejected from the nozzle andstrikes these buckets to transport its momentum, and deflected at an angle and splashes away in

tailrace.

Casing:

This is housing of the turbine to provide support and control of the fluid flow. It is mostlyfabricated by the sheets of cast iron.

Buckets:These are the main parts on which water strikes and transfer its momentum.

When the fluid strikes these buckets its flow velocity is distributed into three components eachalong on direction of rectangular coordinate system.

These components of flow velocity are Vr, Va,Vu, radial, axial and tangential velocity

components. By using Vector Algebra one can correlate the power of turbine to these velocitycomponents. These velocity components form the velocity triangles.

Tail RaceThis is used for water extraction to the down race of river.



Design of Impulse Turbine

The design of Impulse Turbine consists of the design of following things.

1) Nozzle design

2) Bucket design3) Runner design

4) Pulley design

The formulas used for this purpose are.

1) ! gzV

p

P

2

2^Constant

2) A1V1=A2V2

3) Vexit= gh2

4)

Runner Velocity= 60

** N D pie

5) Relative Velocity=Runner-Jet Velocity6) The rate of work done on the rotor=

Work=Angular velocity*(R2.Vt2-R1Vt1)*Mass flow rate

Where Vt are the tangential Velocity Components

Design DataFlow rate 60 l/minPower of Pump .5 Hp

Blade deflection Angle 120 degree Nozzle exit Velocity 19.1m/s

Impeller Velocity 8.8 m/sRelative Blade Velocity 10.3 m/s

Flow Velocity at inletVw1=V1= 19.1m/s

Flow velocity at exit Vw2= -1.15 m/sImpeller R PM 840 rpm

Impeller Dia 20 cmJet Dia 9 mm

Power output 184 wattsEfficiency 70 %

Nozzle Inlet 60 mm Nozzle Exit 9 mm

Bucket Length 20 mm

Bucket Width 40 mmJet Ratio 20

Number of Buckets 10



Pressure Drop acrossnozzle 181665 Pa

Pressure in the base of Nozzle 10 meter Hydraulic Power 262.2 watts

Wheel Power 236 Watt

Turbine Power With 70% efficiency 175 watts

Manufacturing



This portion of the project consists of Technical Drawings, Cost estimation, Bill of Material,Procurement, Workshop Operations, Assembly and at the end Dispatch.

I attached the Technical Drawings and in the following lines Bill of Material.

Bill of Material

Item Cost

Runner 6000Casing 10000

Nozzle 300Shaft 300

Bearings 300Belts 300

Pulleys 1000Generator 2000

Tank 500Pump 2000

Pipes 300Suction Valve 200

Seals 100Lights 1800

Labor Cost 5000

Total Cost 30,000 Rs

This may fluctuate due to some addition of measuring instruments and taxes.

Material forming operations are performed in the Chiral Engineering Works.On the Next Few Pages Technical drawings are attached.

Views of Apparatus



There are some actual pictures of the system with labels of different components.

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Operation Manual

1) Unit Description

The basic purpose of this unit is training and experimentation. This apparatus can successfully

depicts the principals of Pelton wheel and its operation. In this unit the flow of water can beadjusted by Needle Assy and also Flow control valves. The load on the shaft can be placed by

the help of spring balances. And the values of different turbine characteristics can be calculatedand plotted on the graph paper. The supply of water is provided by the centrifugal pump. In this

unit the pressure of water is 1 bar.

2) Components of the System

1) Pump 4) Turbine Casing

2) Nozzle 5) Spring Balance3) Needle Assy 6) Buckets and Runner

1) Table 8) Water Storage Tank

7DEOH 3XPS



9) Flow Control valves 10) Pressure Gauge

And different pipes like Suction and delivery pipes

Now first off all fill the tank with water and then priming operation perform. Now you are in

position to ON the power supply. This will start the pump and Turbine will rotate by the jet of water impinging on it.

Preparing the Experiment

To prepare for the experiment the following steps should be followed1) Charge the Water Storage Tank

2) Perform the Priming Operation3) Open the Valves

4) Adjust the Needle Position to Fully Open state5) The spring load should be zero at start

6) ON the Power Supply

Formulas for Calculations

Determine the Volumetric Flow

To determine the volumetric flow fill the tank of knownvolume in a given time you will find the answer.

Determine the Rotational Speed

To determine the rotational speed use the Non-Contact type

Tachometer.

Determine the Pressure Head

This is corresponds the pump pressure applied upstream of the turbine this can be read from the reading of Pressure Gauge.

H= p / g.h

Determine the Torque

This unit has the accessories for measuring the torque. By

the spring balances you can apply the load and multiplying it with the radius of shaft you canfind the value of Torque.

Determine the output Power

Pout=M.2.pie.n/60



Determine Hydraulic power

Hydraulic power can be calculated by the following formula.

Phyd=V.H.p.gEfficiency

Efficiency of the turbine = Output Power/Hydraulic Power

Proposed Experiments

Power Characteristic Curves

Turbine Characteristic Curves

Turbine Characteristic Curves

Rotational

SpeedR PM

Braking

Force N

Moment

On theShaft

N.M

Power on

the shaft

W

Hyd.power

W

Efficiency

In the same way we can change Flow rate and at the same time we find the power for each flowvalue.

Perform the Dimensional Analysis and find the Dimension less parameters of Turbine.

Future Proposed Work

There are many deficiencies in this project theoretically and practically so

2) First Future work should be to point out these deficiencies

3) Establish the feed back mechanism to regulate the water supply against the varying load4) Establish the Multi jet striking system



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